Tube joining



J. J. CULLEN TUBE JOINING June 20,1950

Filed May 3, 1945 FIG.

FIG

ATTORNEY June 20, 1950 Y J. J. CULLEN 2,511,836

TUBE JOINING Filed May 3, 1945 FIG. 8.

'4 Sheets-Sheet 2 IN VENTOR JOHN J. CULLEN ATTORNEY June 20, 1950 J. J.CULLEN 2,511,336

TUBE JOINING Filed May 5, 1945 4 Sheets-Sheet s IO6 9o 98 86 11 7s 89IOQFIG. 20.

m- INVENTOR JOHN J. CULLEN ATTORNEY June 20, 1950 I J, CULLEN 2,511,836

, wuss JOINING v Filed llay 3. I945 4; l;ee ts-Sh eej; 4

INVENTOR JOHN V J. CULLEN FIG. 36.

ATTORNEY Patented June 20, 1950 UNITED STATES PATENT .OFFICE 2,511,836.f I TUBE JOINING John J. ouuen, Brighton, Mass. Application May 3,1945, Serial Nb. 5913 2 Claims. (o1. 29-1482) I (Granted under the actof March 3,1883, as

amended April 30, 1928 370 Q. G. 757) My invention relates to tubejoining. More particularly, it relates to the joining of pieces ofthin-wall metal tubingin angular relationship to each other. It dealswith a method and apparatus for forming the necessary interfittingportions on a main tube and a branch tube for connecting the tubestogether in angular relationship.

The method used at present to join thin-wall tubes in angularrelationship is a hand method which is both laborious and slow and is,therefore, costly. Furthermore, the hand method necessitates the use ofextreme care to attempt to obtain accuracy and often results innon-uniform products.

In joining the tubes, it is the practice to form on the side of the maintube, at the location where the branch tube is to be connected, asuitable boss. On the end of the branch tube which is to be connected tothe main tube, a saddle, which is complemental to the boss, is formed.The saddle is fitted over the boss and the main tube and branch tube aresuitably secured together, for example, by soldering.

To form the boss on the side of the main tube, it is necessary, with thehand method, to first locate exactly on the side of the main tube, thecenter of the branch to lead therefrom. The main tube is then held insuch a position that the center mark is uppermost and by use ofdividers, a circle is scribed on the tube. This circle has a diameterequal to the inside diameter of the branch less the thickness of themetal of the main tube. Then the cup or boss is raised on the main tube.This is accomplished by first drilling a relatively small hole at thecenter mark which is then filed smooth to prevent cracking during thesubsequent metal-working or hammering operation. The drilling operationhardens the surrounding metal, especially if it is copper or copperalloy, and consequently, it is necessary to anneal such metal tofacilitate the subsequent metal-Working operation. The end of ametalworking pin or bar is then inserted in the drilled opening and byhammering on the side ofthe pin, the metal is worked upwardly to form aflange around. the hole. While hammering, the

pin is moved around the edge of the hole to attempt to raise the metaluniformly as the hole is enlarged. This operation causes the raisedmetal and the adjacent metal of the tube to harden, and it is necessaryto anneal the tube from time to time to prevent cracking of the raisedmetal and distortion of the tube itself. Furthermore, it is necessary tofile the edge of the holeirequently to prevent cracking of the metal.The cup or boss is raised until it has any outside diameter equal to theinside diameter of the branch which will be indicated by reaching.

a the circle scribed on the main tube.

To form the saddle on the end of the branch tube -to fit over the bosson the main tube, the following steps are necessary with the hand.method. It is first necessary to lay out a template paper pattern forthe branch so that it fits the circumference of the main tube. Thepattern is then cut out,-wrapped around a tube of a size proper for thebranch, and the end of the branch is marked along the curved end of thepattern. With a hammer-and chisel, the branch is out ofi and the burr isfiled away. The trimmed branch is placed on the main tube to see that itfits snuglyand further filing may be necessary to make-it fit properly.Using. dividers, an arcuate line parallelto'the arcuate end of thebranchis scribed at a-point spaced ashort distance there; from"andis'subsequently used as a guide while turningthe saddle. Since thecutting operation hardens the adjacent metal, especially if it is copperor copper alloy, it is necessary to anneal the trimmed end of the tube.Then using :a bumping hammer or a similar tool, the branch end is workedon the edgeof an anvil. The area from the scribed line to the end of thebranch is worked outwardly until the saddle of proper.

shape and size is formed thereon. During the metal-working operation,frequent annealing will be necessary to prevent cracking of the metal. aBefore the branch is connectedto the main tube, it is usually necessaryto place the saddle over the cup or boss to finally check the fitbetweenthe saddle and the boss. It is often necessary to further .work, theboss up into the saddle.

mustqbe exercised and it is necessary that the workbe performed byskilled labor.

uniformity.

.Oneofthe objects of my invention is to pro,-; vide a methodfor forming.the desired comple mental portions; on sections; of tubing to join.them;in"zangular relationship, the method being.

Even with such care by qualified labor, the resulting produotis .notalways of the desired accuracy and;

portions on sections of tubing to join them in angular relationshipwhich is of such a nature that the complemental portions will be-accurately formed to predetermined dimensions and will be accuratelylocated at predetermined positions.

Still another object of my invention is to provide a method andapparatus bf the type indi cated of such a nature that the complementalportions may be so formed that the sections of tubing can be joined toeach other at. various selected angles.

Various other objects will be apparent from the following description.

According to my invention, the branch-receiving boss is formed on theside of the main tube and the complemental saddle is formed on the endof the branch tube by a novel method and apparatus. The complementalportions on the two tube sections will be accurately formed andlo'cated'so thatthe sectionscan then be connected to each other in thedesired angular relationship.

The branch-receiving boss is formed on the side of the main tube byfirst punching an elongated opening in the form of an ellipse in oneside of the main tube. This tube is usually larger than the branch tubealthough'both may be the same size. The opening is disposed at suchapoint that its center will be at the desired center of the branch to bejoined to the main tube. Also, the opening is so disposed that itslonger or transverse axis extends longitudinally'of the tube and is inthe same plane as the axis of the tube. The opening is of a proper sizeto permit raising of a flange of desired height around it to form a bosshaving an external diameter cor-responding to the internal diameter ofthe branch which :it is to receive. The flange israis'ed by placing thetube in a female die which has a semi-cylindrical channel for receivingit. At right angles to the channel is a circular boss-forming chamberwhich is adapted to receive a male die member. This boss-forming chamberis disposed in surrounding relationship to the opening in the tube andhas a diameter greater than-the transverse axis of the opening in thetube, to permit raising of the flange of desired height aroundthe'o'pening. The male die member is disposed initially within the tubeand is then moved at right angles to the axis of the tube through suchopening into the chamber of the female die member. The male die memberis of such size that it will 'raise the metal around the opening untilit"contacts with the wall of the chamber, thereby forming the upstandingflange. Thus, the desired boss is formed on the tube.

The saddle complemental to the boss is -formed on the end of the branchtube by first trimming the end 'to-a-suitable shape. This shape is suchthat the -'end fits the contour of the main tube when the branch isdisposed on the main tube at the same angle at which it is to beconnected "to the main tube. To form the desired flange on the trimmedend of the branch and, thereby, fdrmthe saddle, the end is placed in afemale die member. This die member has a cylindrical tubereceivingchamber and a semi-cylindrical channel or chamber disposed at rightangles thereto for receiving a male die member. The tube is so disposedin the tube-receiving chamber that its trimmed end extends a selecteddistance into the semi c'ylindrical channel. The male die has acylindrical forming portion which is complemental to and is adapted tobe inserted into the tube-receiving chamber, and a semi-cylindricalforming portion at right angles thereto which is complemental to and isadapted to be forced into the semi-cylindrical channel. When the maledie member is inserted into the female die member, the extending end ofthe tube is engaged by the semiwylindrical portion of the male die andis bent to the shape of the channel in the female die member. Thischannel will be of the same shapeand size as the outside contour of themain tube to which the branch is to be joined. Thus, the desireds'a'ddle is formed on the end of the branch.

After the boss 'or'ithe main tube and the compleme'ntal saddle on thebranch tube are formed as'ind'icated, the saddle is positioned over theboss and the two sections are suitably joined together, as "bysoldering. It will be found that thetwo portions accurately interfit andwill serve to connect the branch to the main tube at the desired angle.

The preferred embodiment of my invention is iliustrated in theaccompanying drawings wherein similar characters of reference designatecorresponding parts and wherein:

Fig. 1 is a front elevational view, partly broken away, of a machinewhich I preferably employ in forming the branch receiving boss on themain tube.

'Fig. 2 is an end elevational view o'f the machine shown in Fig. 1.

Fig. 3 is a transverse sectional view illustrating the main tubepositioned between the cooperating male and female die members used onthe machine of Figures 1 and 2 in forming a boss adapted to receive abranch at right angles to the main tube, the male die member shown beingthe one used in the first step of the forming operation.

Fig. 4 is a similar view to Fig. 3, illustrating the male member used inthe second and final step in the formation of the boss in position inthe female die member.

Fig. 5 is a perspective view of the bottom side of the female die usedin the boss forming operations.

Fig. 6 is a plan view of a short length of a tube having an opening ofpreselected size and shape to facilitate the formation of the 90 boss.

Fig. 7 is a side elevational view of the length of tubing showing theboss formed thereon.

Fig. 8 is a longitudinal sectional view illustrating cooperating maleand female die members for forming a boss adapted to receive a branch atapproximately 45 from the main tube, the male die member shown being theone used in the first step of the forming operation.

Fig. 9 is a view similar to Fig. 8 but taken at right angles thereto.

Fig. 10 is a longitudinal sectional view taken through the female die ofFig. 8 and illustrating the male die member used in the second step ofthe forming operation in position in the female die.

Fig. 11 is a perspective View of the male die member of Fig. 8.

40f Fig. 10.

.on theuend of the branch tube.

Ri -.12 is a similar .viewof the'ma esliemem e Fig. 13 is a perspectiveview of the :buttom. side of. the female die used. in the. formation ofhe 45 angle boss. Fig. 14 is a top plan yiew of a. len th. f. tubingshowing an openingformed therein of preselected .size and shape tofacilitate forming the 45. angle 13055.. ..J Fig. 15 is a sideelevationalNifiW showing ,the. completed 45 angle boss formed-,onthetube. Fig. 16 is a side elevationaleviewiofamachine .which I preferablyemployinzforming the. saddle Fig. 17 is a longitudinal .sectionalwiewillustrating the cooperating. male. and female, die

members used on the machine .of Fig.;{.16 in. forming the 90 saddle, theend of. the,;branch being -in.position therebetween. 1... 1. 1

Fig. 18 isaview. similar to Fig. 17. but'taken at .right anglethereto... I

Fig. 19 is an enlarged perspective view of, the male die member used forforming the 90. saddle.

Fig. 20 is an enlarged perspectiveviewillustrating the female die memberusedforforming' the 90 saddle.

Fig. 21 is a side elevational view illustrating 'the manner in which theend .of the branch is trimmed to facilitate formation of the 90..saddle.

Fig. 22. is a view similar to. Fig. 21 but taken at right. anglesthereto.- I

. Fig. .23 is aview similar to Fig. 21 butshowing the 90 saddle formedon the .end of. the branch. Fig. 2i is a view. similar .to Fig..23..but.taken at right angles thereto. 1

Fig. 25 is a detailed viewymainly in. section, illustrating the femaledie member used informingthe 45 angle saddle, the male die.member whichisused in the first forming. operation being shown in position thereinwith the: end of. the branch being positioned between the; two diemembers.

I 1 Fig. 26 is a similar view. illustratingthemale die member used inthe final. 45? saddle forming operation positioned in the female diemember. Fig. 27 is a perspective view; of the male die member of Fig.25. Fig. 28 is a perspective view member of Fig. 26. Fig. 29 is aperspective-viewer .thei'emale die member shown in Figs. 25 and 26..

Fig. .30 is a side elevational view.,; illustrating howthe end of thebranchis trimmed tofacilitate formation of the 45 saddle.

1dr the mat die Fig. 31 is a view. similar to Fig. but taken at rightangles thereto. v 3 Fig. 32 is a similar view to, Fig.- 3Q illustratingthe-45 saddle formed on the end of the branch.

Fig. 33 is a view similar to Fig. 3 2 but taken at right angles thereto.

4 b Fig. 34 is a transverse sectioinaliview through the main tubeand-associated 905. branch illustrating how the two members interiit andare secured together.

Fig. 35 is a side elevational view, partly broken 6 away, of thestructure illustrated in Fig. 34.

Fig. 36 is a view, partly inside elevation and partly in section,illustrating the 45 angle branch positioned on the main tube. .tratedinFigs. 1, and 2 a machine uponwhich the boss forming dies are adaptedto be mountedfor actuation. This machine comprises a table I p n t upperr ace ,of wh c -ris su p te to support the dies and the actuating means,for :the dies.

The standard 2 consists of a. pair of vertically disposed supportingPlates 3. These plates are laterally spaced on the table I and each ofthem has a horizontal flange 4 which rests on the upper surface of thetable and. which is bolted thereto by bolts 4a. Each of the plates 3'has a lower vertically disposed section 5, which carries flange 4, anintermediate forwardly and upwardly curved section 6, and an uppervertically disposed section I. The lower edge of the section 1,indicated by the numeral Ia, is horizontally disposed at a point spaceda, suitable distance above the upper surface of the table. It will benoted in Fig. 2 that the section I of the plate and, consequently, theedge Ia is disposed forwardly beyond the front edge of the table. Theplates 3 are rigidly joined together by a vertically disposed rear plate8, which has its ends bolted thereto by the bolts 9 adjacent the upperends of plates 3, and by a horizontally disposed plate ID which isbolted by bolts I I to the extreme upper ends of the plates 3.

Mounted for vertical movement between the plates 3 is a slide I2. Thisslide has the lower end of a piston. rod l3 threaded thereinto, as atI4. The rod I3 extends upwardly through a packing gland lfi into avertically disposed hydraulic cylinder IS. The cylinder I6 is carried bythe horizontal plate ID. The cylinder l6 has a piston I'I disposedtherein which is connected to the upper end of the rod I3. Mounted abovethe hydraulic cylinder I6 is an air cylinder I8. The cylinder I8 has apiston I9 therein which is connected to the piston IT by a vertical rod20.

A. hydraulic pump 2l is secured to the upper surface of table I and maybe of any suitable type. The pump is connected by a line 22 to the lowerend of the cylinder IS. The flow of fluid to and from the cylinder I6 iscontrolled by a valve 23 of a suitable type. The valve 23 may be openedto connect the pump 2| to the lower end of cylinder I6 and by actuatingthe handle 24 of the pump, fluid will be forced into thelower end ofcylinder I6 and will force the piston II upwardly. This will also forcethe piston I9 of the air cylinder I8 upwardly. The upper end of cylinderI8 is connected by a line 25 to a valve 26 of a suitable type. The valve26 will serve to connect the line 25 either to an air pressure line 21orv to a vent 28. At the time the hydraulic piston I1 is moved upward,the valve 28 will be in such a position as to vent the line 25. To movethe slide I2 downwardly, the valve 23 is actuated to permit hydraulicfluid to fiow from cylinder IS, through line 22, back into the pump 2!At the same time, the valve 26 will be in such position as to connectthe pressure .force, while air pressure will move the slide I 2downwardly and more quickly than the upward movement. Thus, means isprovided for moving the slide l2 vertically relative tov plates 3. 'Anindicating pointer I2a may be attached to the H v b front side of theslide I2 for cooperation with Withreferenceto the drawings I have illus-.70

suitable calibrations on the forward edge of one of the plates 3 toindicate the vertical position of the male die member, as will appearlater. The slide I2 is in. the form of an. inverted box and a link 29,extends upwardlydnto the ayertical standards-aimsstanda dzris-.adapted.;-, ql pp tiq thei's t. .T ppe tfiudfi sth f9fi11$886 Z Lliiil pivotedat a point nn'dway 'be'tween the anii mldway btweeri lts'efidsfithere chromed an sides of slide l2 by means of a pin 30. Thelink opening extending through the top of the die n -is providedwith'abifurcated lower en'd3l, wvhich- 'produces a siibstan-tiallycylindricalformeas indicated in'Figs. 3-an'd4. :AsWill later appear, ing chamber5El disposed 'at rightangles to the -this bifurcated lower end 3 isadapted to receive ch l 49.

a -cooperating lug" formed on a male die member. Each -ofithe-male diemembers is provided'with Iheend3 I-' carries-a'pin-32 which-extendsthrough aan upwardly xteriding lugfi lfadapted'to'b i'djg alignedtransverse openings 33 formed therein. -'"p0sed"'-in 'theibifurcated.rnd 3i1oftther1ifik T which is s d v1J0 Carry 2B. The lug 5| is Providedwith a transverse female' die, is adapted to 'be mounted in horizon-i 10opeping f receiving th pin 32, The lug 5|"wi11 *tal position on thelower edgesla ofthe vertical fib 'tig-htly-iwithjn-the.end:3|I0f'lthe11111;, *sections' 1 ofthe plates-t. Iheplate 34 carries 'As illustratedbestin FigS.-3 and"4,the t0p 0f mmea'chend-an-angle membeftt suitablysecured the 'female die "member 48 .is "provided "with T-thereto. Eachangle member cooperateswith the threaded sockets 5z:fortreeeivin ;t x -rt top surface of the plate s i to form a channelfor 15 '39-carrie'd by'ithei 'plate u. 1- It will'be apparent ireceivinga tongue 36'fastenedto the outersurthat withf the female die' 'member 48rzsecure'd'to faceof'eachplate 3 in alignment with the edge 'the' plate i withithef platepositioned ontth'e la thereof. Thus, the die-carrying plate 34 maysstandai d' l' and with 'one bf them-ale die'membe qui'cltly mounted onthe standard' z by slipping bers suspended by the link:29;?themale'die'memthe angle: members 35 over'the' tongues tt. The iizober nay be move'd upwardly-through the chamupper surface of platedd willabutedgesia while ber 50 of th female die member-by raising the "theinner-edges "of angle members '35 "will e-but sli'de l2.

'the outer surfaces of the plates'tfOne of the plates ln fo'rming a 90angle Lboss according to' my '-"'3*carries'a sleeve3'l on its outersurface at a point -methodiand' withitheapparatus described, I 'first"slightly above the edge la. This sleeve 3'! carries 325 l-talke a'length of main tubing 53' (Fig. 6)'and'form a pin 38 which maybe movedvertically therein an elliptical opening 54 therein. This opening- 54*and relative to aligning openings formed in the may bei punched'or'iotherwise formed in the'side adjacent angle member'35 and tongue36. When 0f"the"t1'1be." Thdcenter of' this openin the' plate 34 ispositioned on the standard 2, the located at the centertofthbranch toextend from *pin 38 will extend into the aligned openings in 93 i theltll'be-l il *TheopenmgI M' willxexten'dilengthmembers35 andtt and willserve to lock the wise of the tube with its transverse axis inthe *plate34 in position. Thus, horizontal and vertical rsam 'r ane as taxisefithe u p "movement of the plate 34 relative to thestandar'ding'fifisrdf apredetermined'siz toz-permit raising "*2 will beprecluded. ofi a fiangei 6f desired heightraround it to form the i Theplate' 3 i, as previously indicated, isadapted i355 cylindrical boss 55(Fig. l7) ihavlng an external *to carry the female die member of theboss formniameterlcorrespondirrg to thezinternal diameter Ing die. Thedie member will be bolted thereto of the' branchiwhich it is to.receive. The trans- "by-means of screwbolts 39,-as indicated in Figs.'=verse axis rof the opening willbe of alength 1, 3, and' i. Theplatefifiis provided with alarge, :e'qualrto" the deslrd 'internaldiameter of the boss 'centrally disposed opening 46 extending com- '4055 less the total height'irof the two portionsof' the :pletely'therethrough. This opening lllwill receive flange raised at the' ends ofthe' open'ing and which *the'lowerend of 1ink29 and is adapted to permitwill extend upwardly from the highestpointon the male die member to passupwardl through the tube. The' conjugate axis 'o'f the .opening 54 theplate, as Will later appear. The die carried :W'illbe of a'len'gthtequal'tmthe 'diameterof the "by plate 34 may be easily removed,by removing boss 55les's the-height of 'the" two portions of the "boltsSS, and bereplaced with a die of di'fierent flange'raise'd at the-sidesof the'opening. Thus, a size. On the other hand, 'if preferred, severalflange can be raised around theopenin'g'and thls "of-the plates fit maybeprovided for carrying flange will' have alevel upper edge, as shown indiilerent size dies and maybe quickly'm'ounted Fig. 7. 'on thesta-ndard2 orbe removed therefrom. "Toraise'the flange in'theman'ner indicated to'Attached to the table l, ubstantially midway produc the boss 55,'the't11be53with theopen- "betweenthe plates 3, and extending outwardlying 54"formed therein is placed upwardly within from the tableis-ahorizontal Supp ng arm-4|. thechannel lll'o'fthe femal die '48, the'diebeing This arm carries a splitsleeve or collar 42 on carried by theplate '34jwhich ismounted'onthe itsouter end'w-hich is in axialalignment with a =gtand rd 2'. The channel 49 has the same oonhe p g 49in the plate 'The Sleeve M tour as the outer surface ofthe tube 53.'Thetube receives a post 43 which may be adjusted veriis=suppoi-bedibythe which i djuste'd t tically therein. The post "43 may be held in anythe proper vertical position. The tube 53 'is so .desired positio ymeans f n eccentric locking 'posltioned-that'th'e opening "54 iscenteredrela- 'device 44 which will actuate the split sleeve' t2 to 0tive to the forming chamb'er50 in the die '48, it grip the post. T pperend of the post -43 being understood thata selected area'o'f th metalcarries a horizontally disposed tube supporting "surr midigg'theopeningill will'extendinwardly ithedlsk t5. from'allfiire'ctions towardsthe center of the In Figs. v3 to'-5, I have illustrated'the diememchamber 50 beyond the wall thereof. Since'the bers which are used informing the 90 angle'boss "diameter or the-chamber 50 corresponds to theon th tube. In this operation I preferably emexternal diameterof theboss55to be formed,an'd 'ploythe two male die members 46 and 41 and asince-thesizeidfand shape of the'opening 5 4 is single female die member'48. The die members preselected 'as indicated above, the area of th'e46 and 41 are substantially bell shape. The memmetal extending inwardlybeyond'the wall of -the "ber 41 is of somewhatgreater diameter than the'm "chamber50' -wi1l bejust sufficient to form the up- 'member 48. Thefemale die member is shown'in *s'tandingfiange which' wil1 produce'the'cylindri- .inverted position in Fig. 5. It comprises a tube- "calbos's"55. receiving channel 49 which is formed on the lower The flangeis preferably raised in two successide of the die'and extends lengthwisthereof. sive operation's' by employing"flrst"the male-dieThe-"channelw-is substantially semi-cylindrical menilzier 48 i-Eig.3')-= antl thenthe' male rliein'em ber 41 (Fig. 4-) To accomplish this,the die member 45 is first positioned in the tube with the lug 5iextending upwardly through the opening 54, as indicated in Fig. 1. Thepin 32 is used to attach lug "5| to the link 29. The slide I2 is thenraised. This pulls die member 46 upwardl through the opening 54. Thetapering side of member 46 engages the edge of opening 54 and graduallyraises the surrounding metal and presses it outwardly, in the mannerindicated in-Fig. 3. Th metal is bent without contacting the wall of theforming chamber 50 even a the die is pulled completely through theopening 54 and out of the tube, due to th fact that the largestdiameter. of die 45 isconsiderably less than the diameter of chamber 50.a

The next operation employs the male die memher 4'! (Fig. 4) which is oflarger diameter, and which is positioned in the tube 53 with its upperend extending through the partly formed boss. The male die member 4'! isattached, as before, to the slide I2. which is raised to pull the dieupwardly. As the member 41 is pulled upwardly through the partly formedboss, it completes the formation of the boss. The greatest diameter ofmember 41 is equal to the internal diameter of chamber 50 less twicethethickness of the metal of the tube 53. Consequently, as the member 41 israised, it willpress the metal of the partly formed boss intocontactwith the wall of cham-.

ber 50, as indicated in Fig. 4, and will form cylindrical boss 55,illustrated in Fig. 7. It is PIB-r ferred to draw the metal, surroundingopening 54 to form the boss in two successive operations rather than ina single operation to prevent cracking of the metal. However, it will benoted that metal extending completely around the opening is raisedsimultaneously, as distinguished from the hand method where only smallsections are raised by successive contact of the pin with the edge ofthe opening. Better and more uniform results will be obtained with mymethod.

The boss 55 will serve to connect the branch at right angles to the tube53. However, it is often desirable to connect branches at other angles.In Figs. 8 to 15, I have illustrated die members for producing a bossfor connecting a branch to the main tube at an angle of approximately45.

In forming a 45 angle boss, I first take a. length of main tubing 56(Fig. 14) and form an opening 51 therein. Theopening 51 will be similarto opening 54 (Fig. 6) except that it will be more elongated since theboss 58 (Fig. 15) to be produced in this instance must be of ellipticalform. The boss 58 will have a beveled shoulder 59 at one end and acurved shoulder 6|] at the other end formed on the upstanding flange.The elliptical boss 58 will have transverse and conjugate axescorresponding in lengths to those of the elliptical end of the branchwhich the boss is to. receive. Therefore, the corresponding axes of theopening 51 will be the same lengths, less the height of the portion ofthe flange raised at the ends thereof, as those of the boss. The diemembers which I employ in forming to the 45 boss include the two maledie members BI and 62, illustrated in Figs. 8 to 12, and a single femaledie member 63, illustrated in Figs. 8, 9, and 13.

The male die member 6| has the shape illustrated best in Fig. 11. It isof elliptical cross-section and has a vertical lower surface Bio and aninwardly tapering upper forming surface 64. It is provided with anupstanding lug 65 for connecting it to the link 29 depending from theslide The male die member 62 is considerably longer than the die memberBl although it has a midportion of the same width as the mid-portion ofdie 6|. It i of elliptical cross-section and has an inwardly taperingforming surface 66 which extends completely therearound with theexception of one end thereof. At'this'end there is formed a bluntvertical lower endportion 61 and an upper concave forming surface 68.Attached to the upper top surface of the die 62 is a lug 69 which isused for connecting'the die to the link 29.

The female die member 63 is-shownin inverted position in Fig. 13. Itcomprises a tube-receiving channel 10 which isformed'onthe lower side ofthe die and extends lengthwise thereof. "The channel 10 is substantiallysemi-cylindrical and is of the same contour as the outer surface of thetube 56. Midway between-the ends of channel Ill, there is formedanopening extending through the t0p-0f the die which produces a formingchamber-1|. The forming chamber II is mainly of elliptical form with itstransverse axis in the same plane'as the axis of channel HI. As bestshown in Figs. 10 and 13 at one end of the cham ber '11 there isaconvexsurface I2 complemental to the surface 68 formed'on the end ofthe male die member 62. The remaining surface of the chamber II iscomplemental to the surface 65 of the-male die 62. I I

To raise the flange inthemanner indicated to produce the boss58,.thetube-5G with the opening 51' formed therein. is placedupwardlywithin the channel). of thefemale die 63, the die being carried-by theplate-34 on the standard 2. The tube is supported by'the disk-'45. Thetube 56 is so positioned-that the opening 51 is centered relative totheforming chamber It in the die 63. A: selected area of the metalsurrounding the openingET-will extendiinwardly from all directionstowards-the center of the chamber H be-. yondthe wall thereof, Since thesize and-shape of the chamber H correspond to that of the boss 58 tobe-formed, and-since the size and shape of the opening51 is preselectedas indicated above, the area of themetal extending inwardly beyond the-,wall of the chamber 1 twill-bejust sufiicient to form the upstandingflange and will produce the ellipticalboss 58. i I Y The flange ispreferably raised in two successive operations by employing first themale die member 6| (Fig. 11') and then the male die mem-- ber '62(Fig.-12). To accomplishthis, the die member 6! is first positioned inthe tube with the lug 65 extending upwardlythrough the opening 51. Thelug 65 is attached to link-29 and the slide "is then raised. This pullsdie;member 6| upwardlyithrough the opening 51. The tapering formingsurface 64 of'the' die engages the edge "of opening 59. and graduallyraises the surrounding metal and presses it outwardly, in themannerindicated in Figs. Band 9.- As shown in Fig. 8, thewidth ofthemid-portion of the die is the same as that ofchamber 1| less thethick ness of the metal of the tube at each side thereof. Consequently,themetalwill be-pressed against the sidesof -the chamber 1|." However,the metal at the end of the opening 51 will not be'pressed against theends ofthe chamber H, as shown in Fig. 9, due to the fact that the'diemember lit-is shorter than the chamber-H.411 order to permit upwardpassage of the, maledie 6| through the female die 63. 9 1

The next operation employs the male die member 62(Fig. 12). This diememberis alsoposltioned in thet'ube 56 and has its upper end extendingthrough the partlyformed boss. The male die member 62 is attached tolink 29. As the die member 62 is pulled upwardly into the partly formedboss and the complemental forming chamber "II, the formation of the bossis completed. However, it will be noted that the inale die member 62merely moves completely into the female die member 63 and not throughit. The tapering surface 66 will further bend the metal with which itcontacts into forming relationship with the complemental surface of thechamber II. Also, the concave forming surface 68 will bend theadj'a'c'entmetal "into contact with the complemental convex surface I2.Thus. the elliptical boss 58 will be formed with the inclined portion'59 of the flange formed by cooperating stiffaees 66 and TI and'with the'c'onvexly curved portion 60 of the flangeformed by the cooperatingcomplemental surfaces 68 and 12.

It is to be understbod that bosses of other shapes and sizes may beformed by varying the shapes of the 'die members.

In Fig. 16, I have illustrated a machine u on which the saddle-forming*die's are adapted to be inounted for actuation. This machine comprisesa supporting table I3. 011 the top surface of this table I3 at one'e'iid thereof is a die-supporting bed plate M which may be 'wel'ded tothe table. Also at this end is a U-shaped standard I which has its openend directed toward the front of the table. At the opposite end of thetable is everti'c'al standard I6. The standards 75 and 16 are connectedtogether by a top plate I1 which has it's-one ehd bolted to member 76 bybolts I8. The opposite end of plate I! carries an "abutment I9, whichmay b welded thereto, and which abuts the outer surface or standardadjacent its upper "end. A similar abutment 80 is welded to the topsurface of the table I3 and abuts the outer surface of standard I5 'atits lower 'end. The'meihbers 19 "and 8t serve as thrust members toprevent outward movement of the standard 15. curing the metal-armingfarming operatioi as will 1ater wheat. The lower portion of standaid I6has its inner surface abutihg theend of 51' e "M whicnwin servetopr'event inward moveneat cf standard T5. I H

The female die unit, illustrated generally bythe athe sm,merely'rests-"oh the'top surface of'the plate 14. Its outereffd w'iIl 'eg'age the standard I5. Adjacent the inner end o'f'the die unit 81 anupstairs bin '82 is provided on the bed plate 14 for preventing inwardmovement of the unit =8I.

'Oh'the upper "siiiface of 'the table 13 at the end opposite to wherethe late M is disposed, a bed plate 88 "is secured "in a suitable mannerby welding. This -plate 83 has a guid'ew'ay 84 formed therein andextending longitudinally thereof. This guidew'ay receives suitable guidemembers 85 that' are attached to the lower 'side of a h orizoht'allydisposed hydraulic cylinder 86. Thus,

the cylinder "86 is merited "'for axial movement. I

- The cylinder at has a biston 90 =slidably mounted therein. This pistonis "secured to a. piston rod 9| which projects from the cylinder througha packing gland 92. As shown best in Figs. 17 and 183 the end of pistoniod'9'l is previded With an enlarged disk-like portion 93 which has areduced 'c'ylihdrical shank 94 extending therefrom. This shank 94 isadapted to extend into a cylil'rdiical secket termed 'in'the male' diemember; indicated generally by numeral 96. l

A hydraulic ump 91 is provided for mating the iston in t'he cylinder 86.Thispump maybe 01 any suitable type and is operated by aha'ndle 98. Aline 99 leads from one end of the cylinder 96 to the 'puhip'while asecond line 160 leads from the other "end of the cylinder to the pump.ey actuating a suitable valve IDI, thelines 99 and 'I 99 maybeselectively connected to the high pressure or low pressure side of thepump. Thus by actuating valve I01 and handle 98, the piston 90 and,ccnsequent1y, the rod 9| may be moved in the desired axial direction.

The female die unit "BI includes a tube-holding section I92 and aforming section I93, which are adapted. to be disposed side by side inthe manner illustrated in Figs. ldancl 17. The section 102 is composedof an upp r block 104 (Fig; 16) and a lower block I05 which have semi=cylindrical channels of proper contour and size to receive and clamp thetube upon which the saddle is to be formed. The cooperating blocks I04and I05which embrace the tube are secured in clamping relationship tothe tube by bars I96 which have their lower ends pivoted to blocks 5 andwhich swing into and out of vertical aligning channels formed on theouter surfaces of the blocks. Each bar has threaded on its upper end anut I91. By tightening nuts IIl'I after the bars are swung intooperative positions, the two blocks I94 and I95 will beclam ed together.The forming section I03 of the female die unit is adapted to be used informing the 90 saddle. It is similarly formed of two blocks I98 and I09,as shown best in Fig. 20. These blocks have semicylindrical channelstherein adapted to cooperate to form -'a cylindrical chamber I I9 inwhich the tube will be clamped. These blocks are secured together bypivoted bars I II similar to the bars I06 of the unit I02. The faces ofthe blocks I08 and I99 are provided with aligning semicylindricalchannels which cooperate to produce a forming channel 1I-2 having itsaxis disposed at right angles to the axis of the formin chaznber III].Securedto the outer side of the block 199 and projecting into thechannel II-Z is'a tongue I I3. I

The male die member 96 for cooperating with the section 163 of thefemale die member to form the 96 saddle is illustrated in Fig. 9. Itcomprises a semi-cyiindrica-l forming portion H4 which is complementalto thechannel 'II-2 of the female die -section I63. 0n the curved sideof the portion H4 midway between th ends thereof and at right anglesthereto is a cylindrical shaped forming portion which is comple'rhen'talto the chamber III] of the female die section I03; One end of theportion H4 is provided with a channel I I6 for receiving the tongue I=I3as the male and fem-ale dies are moved into cooperative relationship aswill later appear.

When the male die member 96 is disposed on the piston rod 9I, thecylindrical shank 94 ex tends into "a cylindrical socket I-II (Figs. 17and 18) which is formed at a central position in $5 the fiat surface II8 of the forming portion I'll 13 of the die. To fasten the die to thepiston rod, a screw bolt H9 is provided which is inserted through achamber I20, formed in the portion H of the die, and which is threadedinto the shank 94.

In forming the 90 saddle, the end of the branch tube I2! is trimmed inthe manner illustrated in Figs. 21 and 22. The edge I22 will have such acurvature that it will straddle the main tube 56, to which it is to bejoined, when it is disposed at right angles thereto. To form the desiredflange on the trimmed end of thebranch, and thereby, form the saddle I23(Figs. 23 and 24), theend of the tube I2I is disposed in the female dieunit 8|. It is so disposed in the forming portion I03 of the die unitthat its trimmed end I23 extends a selected distance into thesemicylindrical channel H2, as illustrated in Fig. 16. To properlyposition the end of tube I2I in the die I03 it is merely necessary toalign the outermost extremity I22a of edge I22 with the flat face H8 ofthe die. The portion of the metal extending into the channel H2 will besuflicient to form the flange or saddle I23.

The die unit 8|, in which the tube I2I is clamped, will be positioned onthe bed plate 14 in the manner illustrated in Fig. 16, the outer end ofthe tube extending through the member 15. The male die member 96 ismounted on the piston rod M. The cylinder 86 is adjusted by operatingthe handwheel 89 until the forming portion H5 of the male die extendsinto the end of the tube I2I in the female die section I03. The unit 8Iis shifted laterally to the necessary extent to permit this. It maybenecessaryalso to initially adjust the die 96 about the axis of rod 9|until the tongue H3 is guided into slot H6. This properly aligns theforming portion H4 of the male die with the channel H2 of the femaledie. To complete the metal drawing or forming operation, it is' merelynecessary to properly actuate pump 91 to move piston rod 9| in theproper direction. This will force the male die member completely intothe female die member.

As the male die member is forced into the female die member, thecylindrical portion H5 will extend into the end of the tube disposedwithin chamber I I0 and will maintain the tubular shape of the end ofthe tube. The semicylindrical forming portion H4 will engage theprojecting trinnned edge I22 of the tube and will bend it into contactwith the surface of the channel H2 around the end of chamber H0. Thus,all of the material of the projecting edge I22 is simultaneously bent toform the saddle I23 which will be at right angles to the axis of thetube. Consequently, the saddle will be more accurately and uniformlyformed than with the prior art method wherein small sections of themetal are bent successively with a hammer.

As shown in Figs. 34 and 35, the end of the branch tube I2I which hasthe saddle I23 formed thereon, is placed over the boss 55 of the maintube 53. The external diameter of the boss 55 will be the same as theinternal diameter of the tube I2I. The saddle I23 will exactl fit thecontour of the tube 53 around the boss. The branch tube I2I may besecured to the main tube by soldering, as indicated at I24. The saddleand the boss will accurately interfit and will serve to join the tubesections at right angles to each other.

' In forming the 45 saddle for cooperation'with the 45 boss'58 of Fig.15, I employ the die mem-' bers illustrated in Figs. 25 to 29 inclusive.

The forming section of the female die unit is illustrated in Figs. 25,26 and 29. This section I25 is made from two parts I26 and I21. Theseparts are secured together by pivoted rods I28, which cooperate withaligning channels in the two parts in the manner described withreference to the die unit BI. The parts I26 and I21 havesemi-cylindrical channels formed therein which cooperate to produce atube receiving chamber I29 of cylindrical form. One face I30 of thesection I25 is flat and vertically disposed. The other face includes aninclined surface I3I and a vertical surface I32 at the lower endthereof. The surface I3l is disposed at an angle of 45. Joining thesurface of the chamber I29 to the surface I3I and the vertical surfaceI32 is a' saddle forming seat I33. This seat I33 inclines inwardly fromthe surface I32 to its junction with the wall of chamber I29. The seatI33 also inclines inwardly from the surface I3I to its junction with thewall of chamber I29 with the exception of a convex portion I34 at itsupper end.

The male die members for forming the 45 saddle are illustrated best inFigs. 25 to 28. I preferably employ a male die member I35 and a male diemember I36 which are used successively with the female die member I25.The member I35 is adapted to be attached to the piston rod 9I in thesame manner as described with reference to the die member 96 (Fig. 17).This die member I35 comprises a forwardly projecting portion I31, whichis of smaller cross-section than that, of the tube to be formed, and anupstanding forming portion I36. The top surface I39 of portion I31 iscurved to the same contour as the inner surface of the tube to beformed. A forming surface I40 is formed on the forward edge of theportion I38and merges with the surface I39. The surface I40 curvesconcavely in a vertical plane and convexly in a horizontal-plane. Also,it is angularly disposed relative to the horizontal so that it will becomplemental to the convex surface I34 of the female die I25, as shownin Fig. 25.

The male die member I36 is similar to the die member I35 but is oflarger cross-section. It is provided with a forming surface I4I which isof the same outline as the surface I40 of die I35 and which,consequently, will be complementary to the convex surface I34 of thefemale die I25, as shown in Fig. 26. However, the forwardly extendingportion I42 is of larger cross-section than the similar portion I39 ofthe die I35. This extension I42 is mainly of cylindrical form and willfit into the tube to be formed, corresponding in contour to the innersurface thereof. The rear endof the die I36 at its lower edge isprovided further with an inclined forming surface I43, which merges withthe lower curved surface of extension I42. This surface I43 will becomplemental to the inclined surface I33 of the female die I25, asillustrated best in Fig. 26.

In forming the 45 saddle, the branch tube I44 is trimmed in the mannerillustrated in Figs. 30 and 31. The trimmed edge will fit the contour ofthe main tube 56, when the branch is positioned at the angle it is toextend therefrom, which in this instance will be at an angle of 45. Thusthe trimmed edge will have the concave curve I46, as shown in Fig. 31,and the convex curve I41, as shown in- Fig. 30, at right angles thereto,the curve I41 extending at an angle of 15 substantially 45. The open endof the tube will, consequently, be of elliptical outline.

.Theend of the tube I44 is clamped in the female die I25 so that itstrimmed end will extend from the forming chamber I29 of the die asufiicient amount to produce the saddle I48 illustrated'in Figs. 32 and33. To properly locate the tube in the female die, it is merelynecessary to position the outermost extremity I49 thereof insubstantially the same vertical plane as the surface I32 of the die,asshown in Fig. 25.

As shown in Figs. 32 and 33, the final saddle tobe produced will be ofelliptical form and will be disposed at a 45 angle relative to the axisof the branch. Its flange will include an inclined forward section I50and a concave rear section II. It is preferred that this saddle beformed by two successive metal forming or drawing operations to preventcracking of the metal In the first forming operation, the male die I35is employed. This die is forced into the trimmed end of the tube I 44disposed in the female die I25. The only surfaces of the die I35 whichwill. contact with the trimmed end of the tube will be the surfaces I39and I40. The surface I39 cooperates with the top of chamber I29 in thefemale die I25 to maintain the contour of the tube. The surface I40engages the metal adjacent the end of the tube and bends is-upwardly andrearwardly into contact with the complemental forming surface I34 ofthefemale die member. Thus, the complemental surfaces A40 and E34 willproduce the curved section I5I of the saddle.

The next forming operation employs the male die I 35. In this operation,the die I36 is forced into the partly formed saddle and the female diein which the tube is supported. The extension I42 will serve to maintainthe tubular shape of the tube adjacent its end. The surface I M willcooperate with the surface I34 to maintain the shape of the section I5Iof the flange previously formed. The inclined surface I33 of die I35will engage the extremity I49 of the tube and bend it downwardly intocontact with the complemental surface I33 on the female die I25, asshown in Fig. 26. These surfaces I43 and I33 cooperate to produce theinclined section I50 of the saddle.

It is to be understood that saddles disposed at angles other than 45 onthe branch maybe produced by variations in the shape of the male andfemale dies.

The branch I44 may now be mounted on the main tube 45 at a 45 angle.This is accomplished by placing the saddle I48 over the boss 58. Thecurved section I5I of the saddle will interfit with the curved section60 of the boss; The section I53 of the saddle will cooperate with theinclined section 59 of the boss. The two sections may be securedtogether, as by solder indicated at I52. The saddle I48 and the boss 50are ccurately formed so that they will properly interfit and so that thebranch I44: will beconnected to the line 56 at an angle of approximately45.

It will be apparent from the above description that I have provided a,method and apparatus for forming the necessary complemental portions onsections of tubing to permit joining of the sections in various desiredangular relationships. The method is simple, eflicient, economical, andreadily adaptable to modern production methods. The use of dies informing the boss and the saddle will result in extreme accuracy and uni-16 formity. Consequently, it is not necessaryto fit each saddle to aboss with which it is to co operate. Any saddle will fit any boss forwhich: it is designed to cooperate. The saddles and bosses will not onlybe accurately formed so that they properly interfit but also will beaccurately located so that the branch will extend from. the main tube atthe proper position. They will also be so formed that the branch andmain tube will be disposed in the proper angular relationship.

The invention described herein may be manu factured and used by or forthe Government of. the United States of America for government purposeswithout the payment of any royalty thereon or therefor.

Having thus described my invention, I claim;

1. The. method of joining a branch tube and a main tube in angularrelationship, which comprises forming in the main tube an opening ofelliptical outline, the opening being so disposedthat its transverseaxis extends longitudinally of the tube and is in the same plane as theaxis of the tube, the transverse axis of said opening being of a lengthsubstantially equal to thatof the corresponding axis of the branch lessthe height of the flange portions to be raised at the ends of saidopening, the conjugate axis of the opening being of a lengthsubstantially equal to that of the corresponding axis of the branch lessthe height of the flange portions to be raised at the sides of saidopening, simultaneously forcing the entire edge of said openingoutwardly to raise a continuous boss around the opening which has alevel upper edge, shaping the end of the branch tube to fit the contourof the main tube when disposed at the angle it is to be' connected tothe main tube, simultaneously forcing the entire edge of the shaped endof the tube outwardly to form a saddle of uniform width which fits thecontour of the main tube when disposed at the angle it is to beconnected to the main tube, disposing the saddle of the branch tube overthe boss of the main tube, and secur-- ing the tubes together.

2. The method of joining a branch tube and a main' tube in angularrelationship, which comprises forming in the main tube an opening ofelliptical outline, the opening being so disposed that its transverseaxis extends longitudinally of the tube and is in the same plane as theaxis of the tube, the transverse axis of said opening being of a lengthsubstantially equal to that of the corresponding axis ofthe branch lessthe height of the flange portion to be raised at the ends of saidopening, the conjugate axis of the opening being of a lengthsubstantially equal to that of the correspondingaxis of the branch lessthe height of the flange portions to be raised at the sides of saidopening, placing over said opening a female die having an openingtherein corr'e sponding to the shape of the boss to be raised on saidmain tube, inserting a shaped male die into said tube, forcing said maledie outwardly through said opening thereby simultaneously forcing theentire edge of said opening outwardly to raise a continuous boss aroundthe opening which has a level upper edge, shaping the end of the branchtube to fit the contour of the main tube when disposed at the angle itis to be connected to the main tube, clamping the end of said tube in ashaped female die with said shapedend projecting therefrom a preselecteddistance, forcing a shaped male die against said projectiing end therebysimultaneously forcing the yen- 17 tire edge of the shaped end of thetube outwardly to form a saddle of uniform width which fits the contourof the main tube when disposed at the angle it is to be connected to themain tube, disposing the saddle of the branch tube over the boss of themain tube, and securing said tubes together.

JOHN J. CULLEN.

REFERENCES CITED UNITED STATES PATENTS Name Date Youngs Dec. 21, 1886Number Number 18 Name Date Higgins Apr. 14, 1896 Chillingworth Jan. 4,1898 Halifax Nov. 21, 1899 Sneddon Feb. 11, 1902 McCoy May 14, 1918Kellogg Mar. 2, 1926 Kellogg Jan. 17, 1928 Lewis Mar. 29, 1938 VogelAug. 9, 1938 Ferris Mar. 12, 1940 Cornell Apr. 5, 1941 Nichols Sept. 29,1942 Holmes et a1. Feb. 2, 1943 Kalwitz Oct. 16, 1945

